Chassis with distributed jet cooling

ABSTRACT

A chassis with distributed jet cooling is provided. The chassis includes one or more sidewalls defining a volume configured to substantially surround one or more heat generating components positioned within the volume. The chassis further includes at least one array of fins thermally coupled to a respective one of the one or more sidewalls and at least one synthetic jet assembly comprising a multi-orifice synthetic jet or a number of single orifice synthetic jets disposed on a side of a respective one of the array(s) of fins. The chassis further includes at least one attachment means for attaching a respective one of the at least one synthetic jet assemblies to a respective one of the one or more sidewalls.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of, and claims priority to,U.S. non-provisional application Ser. No. 12/759,899, filed Apr. 14,2010, which claims priority to U.S. Provisional Patent Application, Ser.No. 61/262,722, filed Nov. 19, 2009, the disclosures of which areincorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention relates generally to thermal management systems, and moreparticularly, to thermal management systems with distributed jet coolingto augment convection heat transfer.

Recent advancements in electronics technology have produced nanometersized electronic circuits. The resulting advanced electronics, althoughsmaller, have higher heat fluxes. Because thermal real estate has beenshrinking, advanced cooling techniques are needed. Cost, size,reliability, and availability have been major constraints.

Natural convection air-cooling is the method of choice for many lowpower electronics applications due to cost, availability, andreliability. However, its performance is limited due to buoyancydependent flow. Therefore, there is a need for further enhancement ofnatural convection, in order to cool modern power electronics. Enhancednatural convection will allow higher heat dissipation and still largelymaintain the simplicity of passive cooling.

Synthetic jets are small-scale turbulent jets formed from periodicsuction and ejection of the ambient fluid. The jets may impinge upon aheat transfer surface enhancing convection cooling. Likewise, they mayflow parallel to a heat transfer surface, also enhancing convectioncooling. The small size of these devices, accompanied by a high airvelocity, could enable a significant reduction in the size of thermalmanagement hardware for power electronics. Synthetic jets arehistorically used for boundary layer control applications. However, theyhave also been shown to augment natural and forced convection heattransfer.

Although studies indicate that heat transfer augmentation is possibleusing synthetic jets, there is limited data available for theapplication of synthetic jets to large heat sink surfaces. In addition,new attachment means are needed for reliable attachment of syntheticjets to a chassis. Accordingly, it would be desirable to understand theinteraction between main flow and synthetic jet flow and to exploit thisinteraction to achieve heat transfer enhancement for large heat sinksurfaces, such as chassis cooling applications. It would further bedesirable to provide reliable attachment means to attach synthetic jetsto a chassis.

BRIEF DESCRIPTION

One aspect of the present invention resides in a chassis withdistributed jet cooling, the chassis comprising one or more sidewallsdefining a volume configured to substantially surround one or more heatgenerating components positioned within the volume. The chassis furtherincludes at least one array of fins thermally coupled to a respectiveone of the one or more sidewalls and at least one synthetic jet assemblycomprising a multi-orifice synthetic jet or a number of single orificesynthetic jets disposed on a side of a respective one of the array(s) offins. The chassis further includes at least one attachment means forattaching a respective one of the at least one synthetic jet assembliesto a respective one of the one or more sidewalls. Another aspect of theinvention resides in a chassis with distributed jet cooling, the chassiscomprising one or more sidewalls defining a volume configured tosubstantially surround one or more heat generating components positionedwithin the volume and at least one array of fins thermally coupled to arespective one of the one or more sidewalls. The chassis furtherincludes at least one synthetic jet assembly comprising a number ofsingle orifice synthetic jets disposed on a side of a respective one ofthe array(s) of fins. Each of the single orifice synthetic jets isconfigured to direct a jet at an end of a respective one of the fins andcomprises an orifice. At least a subset of the orifices have an openinglength L in a range of about three (3) millimeters (mm) to aboutseventeen (17) mm. The distance d between a respective one of theorifices and the respective end of the fin is in a range of about onemillimeter (mm) to about seven (7) mm.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 shows a chassis without a synthetic jet assembly;

FIG. 2 shows two sidewalls of the chassis equipped with respectivesynthetic jets assemblies;

FIG. 3 illustrates a snap-in configuration for attaching the syntheticjets to the chassis sidewalls;

FIG. 4 shows a c-clip holder, in perspective view;

FIG. 5 is a cross-sectional view of the arrangement shown in FIG. 3 andshows a row of slots formed in a sidewall for receiving e- or c-clipholders for the synthetic jets;

FIG. 6 illustrates a bent e-clip arrangement for attaching the syntheticjets to the chassis;

FIG. 7 illustrates another example arrangement for attaching thesynthetic jets to the chassis;

FIG. 8 illustrates a rod-and-frame arrangement for attaching thesynthetic jets to the chassis;

FIGS. 9( a)-(c) are top, front and back views of a first portion of apartially enclosed packaging arrangement for mounting the synthetic jetson the chassis;

FIG. 10( a) and (b) are a top view and a front/back view of a secondportion of the partially enclosed packaging arrangement;

FIG. 11 is a front view of the assembled partially enclosed packagingarrangement;

FIG. 12 illustrates a synthetic jet package with diverted airflow thatincorporates a symmetric plate;

FIG. 13 illustrates a two-plate configuration of the synthetic jetpackage shown in FIG. 12;

FIG. 14 depicts an example configuration for a multi-orifice syntheticjet for use in the chassis of FIG. 1;

FIG. 15 illustrates the operation of a single-orifice synthetic jet;

FIG. 16 further illustrates the operation of a single-orifice syntheticjet;

FIG. 17 illustrates a v-groove plate fin configuration;

FIG. 18 illustrates the spacing d between a synthetic jet and a fin;

FIG. 19 shows three different “on fin” arrangements of synthetic jetsand fins;

FIGS. 20 shows an orifice for a jet with an opening length L; and

FIG. 21 is a cross section of FIG. 20 taken along AA.

DETAILED DESCRIPTION

A chassis 10 with distributed jet cooling is described with reference toFIGS. 1-17. As shown for example in FIG. 1, the chassis 10 includes oneor more sidewalls 12 defining a volume (not shown) configured tosubstantially surround one or more heat generating components (notshown) positioned within the volume. The heat generating components maybe any component requiring cooling, non-limiting examples of whichinclude high power processors and power electronics. The chassis furtherincludes at least one array of fins 14 thermally coupled to a respectiveone of the one or more sidewalls 12. For the arrangement shown in FIG.1, the fins 14 are longitudinal plate fins. However, other types of finsmay be employed, including without limitation, pin fins. Briefly, theheat from the heat generating components is transferred into thesidewalls, which in turn transfer heat into the fins 14. The fins 14increase the surface area for heat transfer for cooling the heatgenerating components.

As shown in FIG. 2, for example, the chassis 10 further includes atleast one synthetic jet assembly 30 comprising a multi-orifice syntheticjet (not shown in FIG. 2) or a number of single orifice synthetic jets 2disposed on a side 15, 16 of a respective one of the at least one arrayof fins. For the example arrangement shown in FIG. 2, the synthetic jetassemblies 30 are disposed on the lower sides 15 of the respectivearrays of plate fins 14. This example is illustrative, and the inventionis not limited to this example configuration. In addition and as shownin FIG. 2, the chassis further includes at least one attachment means 4for attaching a respective one of the at least one synthetic jetassemblies 30 (including the respective individual synthetic jets 2) toa respective one of the one or more sidewalls 12. The example attachmentmeans 4 shown in FIG. 2 are merely illustrative, and a number ofadditional attachment arrangements are described below with reference toFIGS. 3-13. It should be noted that the invention is not limited to aspecific attachment means.

The operation of synthetic jets 2 can be understood with reference toFIGS. 15 and 16. As shown for example, in FIGS. 15 and 16, each of thesynthetic jets 2 comprises a first flexible structure 32, a secondflexible structure 34, at least one active material 36 coupled to atleast one of the first and second flexible structures, and a compliantwall 38 positioned between the first and second flexible structures anddefining a chamber. As indicated in FIGS. 15 and 16, the compliant wall38 defines an orifice 39 for facilitating fluid communication betweenthe chamber and an ambient environment of the fins 14.

In the illustrated arrangement of FIGS. 15 and 16, the active material36 is positioned on the first flexible structure 32 and on the lowerside of the second flexible structure 34. It should be noted that thelocations of the active materials 36 on the flexible structures 32, 34shown in the figures are purely illustrative, and the invention is notlimited to any specific locations of active materials. Although for thearrangements shown in FIGS. 15 and 16, the active material iscoextensive with the respective flexible structure, in otherembodiments, the active material extends over only a portion of theflexible structure. For example, smaller diameter piezoelectric ceramicplates (not shown) may be disposed on flexible structures 32, 34 insteadof coextensive active layers 36. The active material can take the formof a single continuous portion. Alternatively, multiple discontinuousportions of the active material can be employed to actuate respectiveones of the flexible structures. A suitable active material is one,which is capable of creating stress resulting from an electricalstimulus. The flexible structures 32, 34 may comprise the same ordifferent materials.

Examples of suitable active material include piezoelectric material,magnetostrictive material (magnetic fields from coils attract/oppose oneanother), shape-memory alloy, and motor imbalance (motor with a massimbalance creates oscillatory motion). Within the subset ofpiezoelectric materials, suitable active materials include bimorphpiezoelectric configurations, where two piezo layers are energized outof phase to produce bending; thunder configurations, where one piezolayer is disposed on a pre-stressed stainless steel shim; buzzer elementconfigurations, where one piezo layer is disposed on a brass shim; andMFC configurations, where a piezo fiber composite on a flexible circuitis bonded to a shim. The active material may incorporate a ceramicmaterial.

As schematically depicted in FIG. 2, a synthetic jet driver 40 isprovided to apply an electrical current to the at least one activematerial 36, to form streams of ambient air. The synthetic jet driver 40can be electrically coupled to the active material 36 using wires orflexible interconnects, for example. Briefly, electrical current fromsynthetic jet driver 40 is received by the active material, andtransformed into mechanical energy. As shown, for example in FIG. 15,the active material 36 creates stress on the flexible walls 32, 34,causing them to flex inwardly, resulting in a chamber volume change andan influx of ambient air into the chamber 70, and then outwardly,thereby ejecting the ambient air from the chambers 70 via the orifice39. Similarly, as illustrated in FIG. 16, when the active material 36creates stress on the flexible chamber walls 32, 34 causing them toexpand, resulting in another chamber volume change, ambient air is drawninto the chamber 70 via the orifice 39. In this manner, the driver 40actuates the jets 30.

The synthetic jet driver 40 may be located within the chassis 10 or maybe remotely located. In addition, the synthetic jet driver 40 may alsobe miniaturized and integrated with the synthetic jet. The current maybe provided as a sine wave, a square wave, a triangular wave, or anyother suitable waveform, and it should be appreciated that the currentis not to be limited to any specific waveform. However, it has beenfound that currents having lower harmonics, such as, for example, a sinewave, may be used to provide a quieter synthetic jet 30. The voltagelevel for the electrical current may be between 1 and 150 volts but isnot so limited. The frequency of the current may be between 2 and 300hertz for embodiments requiring reduced noise, and between 300 hertz and15 kilohertz for embodiments that do not require reduced noise levels.

For many of the illustrated configurations, each of the synthetic jetassemblies 30 comprises a number of single orifice synthetic jets 2. Forthe particular attachment configuration shown in FIGS. 3 and 5, at leastone of the sidewalls 12 includes a number of slots 8 disposed on atleast one of the sides 15, 16 of the array of fins 14, and theattachment means 4 are configured for insertion into respective ones ofthe slots 8 and for securing each of the respective single orificesynthetic jets 2 to the respective slots 8. For the example arrangementshown in FIG. 5, one of the slots 8 is empty for illustrative purposes.The arrangement of FIGS. 3 and 5 may be implemented using c-clipattachment means. FIG. 4 shows an example c-clip 4 in perspective view.As indicated, for example, in FIG. 2, the synthetic jets 2 may beattached to the c-clip holders 4 by means of flexible connectors 6. Inone non-limiting example, the flexible connectors 6 comprise silicone“ears.” As indicated for example in FIG. 5, the base of the c-clip 4 issnapped into the slot 8 to securely mount the synthetic jet 2 to thechassis sidewall 12. To further secure the synthetic jets to thechassis, the c-clip holders 4 may be bolted to the sidewall, asindicated in FIG. 5 for example.

FIG. 6 illustrates another example arrangement for attaching thesynthetic jets to the chassis. For the example arrangement of FIG. 6,each of the synthetic jet assemblies comprises a number of singleorifice synthetic jets 2. However, for ease of illustration, only onejet 2 is shown in FIG. 2. In addition to the c-clip configurationdiscussed above with reference to FIGS. 3-5, e-clips may also be used tofasten respective ones of the single orifice synthetic jets 2 to thesidewalls 12. For the configuration shown in FIG. 6, the attachmentmeans comprises a number of e-clips (also indicated by reference numeral4). As indicated in FIG. 6, each of the e-clips 4 has a bent portion 5.As shown, each of the single orifice synthetic jets 2 is attached to arespective one of the e-clips 4, and the bent portion 5 of each of thee-clips 4 is fastened to a respective one of the sidewalls 12. For theexample arrangement illustrated in FIG. 6, the bent portion 5 of each ofthe e-clips is fastened to the sidewall 12 using a bolt 7. Thecross-sectional view for the arrangement of FIG. 6 is similar to thatshown in FIG. 5 with the exception that no slots are needed for thearrangement of FIG. 6.

FIG. 7 illustrates yet another example arrangement for attaching thesynthetic jets to the chassis. For the arrangement shown in FIG. 7, eachof the synthetic jet assemblies comprises a number of single orificesynthetic jets 2, and the attachment means comprise a number of flexibleportions 6. As indicated in FIG. 7, each of the single orifice syntheticjets 2 has at least one flexible portion 6 affixed thereto, and each ofthe flexible portions 6 is fastened to a respective one of the sidewalls12. For the example arrangement illustrated in FIG. 7, each of thesynthetic jets is attached to the sidewall by means of three flexibleportions 6. However, for other arrangements, other numbers of flexibleportions 6 may be employed. In one non-limiting example, the flexibleportions 6 comprise silicone “ears.” The ears may be attached to therespective sidewall with a rod or bolt 7, for example. As indicated inFIG. 7, there may be a gap or no gap between neighboring pairs of the“ears.” According to a more particular example, at least one of thesingle orifice synthetic jets 2 is oriented at an angle relative to thefins 14. This may be accomplished, for example, by adjusting the heightof the bolt used to affix the flexible portion to the sidewall.

FIG. 8 illustrates a rod-and-frame arrangement for attaching thesynthetic jets to the chassis. For the arrangement shown in FIG. 8, eachof the synthetic jet assemblies comprises a number of single orificesynthetic jets 2, and the attachment means comprise a frame 9 and anumber of rods 11 attached to and extending from the frame 9. For theillustrated arrangement, each of the single orifice synthetic jets 2 isattached to two neighboring ones of the rods 11. According to a moreparticular arrangement, the attachment means further comprises a numberof flexible portions 6, wherein each of the single orifice syntheticjets 2 has at least two flexible portions 6 affixed thereto, and whereinthe single orifice synthetic jets 2 are attached to the rods 11 via theflexible portions 6. As noted above, one non-limiting example of theflexible portion 6 is a silicone “ear.” For the specific arrangementshown in FIG. 8, each of the single orifice synthetic jets 2 has atleast three flexible portions 6 affixed thereto. As shown, each of thesingle orifice synthetic jets 2 is attached directly to the frame 9 viaa respective one of the flexible portions 6. In addition, the frame 9may be affixed to the respective sidewall via rods/bolts 13, which areshown in top view in FIG. 8.

FIGS. 9( a)-(c), 10 (a) and (b) and 11 illustrate a partially enclosedpackaging arrangement for mounting the synthetic jets on the chassis.For the arrangement shown in FIG. 11, each of the synthetic jetassemblies comprises a number of single orifice synthetic jets 2, andthe attachment means comprise a partially enclosed package 20. Each ofthe single orifice synthetic jets 2 within a given synthetic jetassembly is disposed within the partially enclosed package 20.

For the example package configuration shown in FIGS. 9-11, the partiallyenclosed package 20 comprises a first portion 22 and a second portion24. FIG. 9( a) is a top view of the first portion 22 of the package.Front and back views of the first portion 22 are shown in FIGS. 9( b)and 9(c), respectively. FIG. 10( a) is a top view of the second portion24 of the package 20, and a front/back view of the second portion 24 isshown in FIG. 10( b). As shown for example in FIG. 9( a), the firstportion 22 defines a number of openings 26 configured to receiverespective ones of the single orifice synthetic jets (not shown). Asshown for example in FIG. 11, after assembly, the second portion 24 isattached to the first portion 22 to cover the openings 26. For theexample configuration shown in FIGS. 9-11, the second portion 24 isaffixed to the first portion 22 by bolts 7.

As indicated in FIG. 9( a), for example, the illustrated partiallyenclosed package 20 further includes a number of gaskets 28. As shown,each of the gaskets 28 is disposed in a respective one of the openings26 and accommodates a respective one of the single orifice syntheticjets 2. In one non-limiting example, the gaskets 28 are formed ofsilicone rubber. Beneficially, the gaskets shield the single orificesynthetic jets 2 from vibrations.

More particularly, and as shown in FIG. 9( b), the first portion 22 isrecessed to provide recessed areas 21 for receiving respective ones ofthe jets and gaskets. In addition and as also shown in FIG. 9( b),openings 23 are provided for jet air, and holes 25 are provided withinthe first portion 22 for jet bellowing. The gaskets 28 position the jetsin relation to the holes 25 and second portion 24 to obtain the neededvolume for jet bellowing. For the example configuration shown in FIGS.9( a)-(c), holes 27 are provided in the first portion 22 for bolting thefirst and the second portions 22, 24 together to form the package 20, asindicated in FIG. 9( c). In addition, holes 29 are formed in the ends ofthe first portion for bolting the package to the respective chassissidewall 12, for the example arrangement shown in FIG. 9( c). Similarly,and as indicated in FIGS. 10 (a) and (b), holes 31 are formed in thesecond portion 24 for receiving the bolts 7. As shown for example inFIG. 11, the partially enclosed package 20 may be attached to arespective one of the sidewalls 12, for example with bolts 7. Inaddition, a vibration damper (or shock absorbing spacers, not shown) maybe disposed between the package 20 and the respective chassis sidewall12.

The invention embraces a number of modifications to the partiallyenclosed package. For example, replace the “L” shaped foot brackets inthe example configuration of FIG. 11 may be replaced with a spacer orbushing made of a soft rubber (or Si) for shock absorption. Anotheroption is to remove the L shaped bracket completely and extend the boltsused to attach the first and second portions through to the chassissidewall to attach the package to the chassis sidewall.

In addition, an open version of the package 20 may be employed forweight reduction. For this arrangement, only enough material is used toform the first and second portions 22, 24 of the package to holdtogether structurally. This open version can be structured as atriangular lattice shape with six “ring” holders for the jets.

In addition, a variety of electrical connections (not shown) may beemployed for powering the synthetic jets. The invention is not limitedto any specific electrical connection configuration. In one examplearrangement, a groove (not shown) is cast in the second portion 24 toaccept wires from jets and route them to a connection outside thechassis. In another example arrangement, a groove is cast in the secondportion 24 for routing wires together. While still in the package, thewires are routed down towards the chassis, for example, throughalignment holes in the chassis and bottom part of the package. In thiscase, the drive electronics (not shown) would be internal to thechassis.

In yet another example arrangement for the electrical connections forthe synthetic jets, the jets are equipped with a relatively small,secure set of leads, which terminate in a robust terminal pad (notshown). For this arrangement, the first portion 22 of the package 20includes an area adjacent to the jet cut-out area with a cut-out (orrecession) for the terminal pad. The second portion 24 of the package 20includes matching pads and embedded wires (and for particularembodiments, printed circuit board type connections) to the terminal padto the drive electronics. For this configuration, the drive electronics(not shown) are external to the chassis. However, this arrangement maybe modified for use with drive electronics internal to the chassis. Inthis case, the wiring is on the first portion 22 of the package 20, tofacilitate routing the wires into the chassis.

FIGS. 12 and 13 illustrate another configuration for attaching thesynthetic jets 2 to the chassis sidewalls, in which the airflow isdiverted. For the arrangement shown in FIG. 12, a lower 42 one of thesidewalls 12 does not have an array of fins, and the attachment meanscomprises at least one plate 44 mounted to the lower sidewall 42. Asindicated in FIG. 12, at least one of the single orifice synthetic jets2 is mounted to the plate 44 and oriented to direct a jet outwards, andthe plate 44 has at least one bent portion 46 for guiding the jet arounda corner of the chassis for incidence upon the array of fins 14 on aneighboring one of the sidewalls 12.

For the particular arrangement shown in FIG. 12, the attachment meanscomprises one plate 44 mounted to the lower sidewall 42. For thearrangement shown in FIG. 12, the plate 44 is attached to the lowersidewall 42 with bolts 7. At least two of the single orifice syntheticjets 2 are mounted to the plate 44 and oriented to direct respectivejets outwards in opposite directions, as indicated in FIG. 12. For thespecific arrangement shown in FIG. 12, the plate 44 has two bentportions 46 for guiding respective ones of the jets around therespective corner of the chassis for incidence upon the array of fins 14on respective neighboring ones of the sidewalls 12. According to aparticular arrangement, a number of the single orifice synthetic jets 2may be mounted to the plate 44 and oriented to direct respective jetsoutwards in a first direction, and a number of the single orificesynthetic jets 2 may be mounted to the plate 44 and oriented to directrespective jets outwards in a second direction. Although not expresslyshown in FIG. 12, this is similar to the arrangement shown in FIG. 13but with rows of jets 2 on either end of a symmetric plate 44.

Although FIG. 12 shows a single symmetric plate 44, this concept mayalso be implemented with two plates 44 a,b, as indicated in FIG. 13. Forthe two-plate configuration, the attachment means comprises a firstplate 44 a and a second plate 44 b mounted to the lower sidewall 42. Theplates 44 a,b may be bolted to the lower sidewall, similar to thearrangement shown in FIG. 12. As indicated in FIG. 13, at least one ofthe single orifice synthetic jets 2 is mounted to the first plate 44 a.Similar to the arrangement shown in FIG. 12, the one or more jets areoriented to direct a jet outwards in a first direction. Similarly, atleast one of the single orifice synthetic jets 2 is mounted to thesecond plate 44 b and oriented to direct a jet outwards in a seconddirection. The relative orientation of the jets is the same as thatshown in FIG. 12. Each of the first and second plates 44 a,b has a bentportion 46 for guiding the respective jet around the respective cornerof the chassis for incidence upon the array of fins 14 on the respectiveneighboring one of the sidewalls 12.

For the particular arrangement shown in FIG. 13, a number of the singleorifice synthetic jets 2 are mounted to the first plate 44 a andoriented to direct respective jets outwards in the first direction, anda number of the single orifice synthetic jets 2 are mounted to thesecond plate 44 b and oriented to direct respective jets outwards in thesecond direction. The relative orientation of the jets is the same asthat shown in FIG. 12. Beneficially, it is not necessary to removeportions of the fins 14 with the arrangements illustrated by FIGS. 12and 13 because the jets 2 are mounted on the lower sidewall 42. Inaddition, the angle at which the bent portions are bent may be selectedto adjust the angle between the air flow from the jets and the endsurface of the fins 14. In addition the spacing between the plate(s) andthe lower sidewall may be adjusted to adjust the relevant distancebetween the end surface of the fins and the vertical airflow.

As noted above, in addition to the single orifice synthetic jets 2, thesynthetic jet assemblies may comprise multi-orifice synthetic jets 30,which are illustrated in FIG. 14. In addition, each synthetic jetassembly may comprise a stack (not shown) of the single or multi-orificesynthetic jets 30, as described in commonly assigned U.S. patentapplication Ser. No. 12/421,068, M. Arik et al., “Heat Sinks withDistributed and Integrated Jet Cooling,” which is incorporated byreference herein in its entirety. As shown for example in FIG. 14, amulti-orifice synthetic jet 30 comprises a first flexible structure 32,a second flexible structure 34, at least one active material 36 coupledto at least one of the first and second flexible structures, and acompliant wall 38 positioned between the first and second flexiblestructures and defining a chamber. As indicated in FIG. 14, thecompliant wall defines multiple orifices 39 for facilitating fluidcommunication between the chamber and an ambient environment of the fins14. It should be noted that the number of orifices shown in FIG. 14 ismerely illustrative and is non-limiting. In one non-limiting example,the compliant wall 38 comprises an elastomer. Other example materialsfor the compliant wall 38 include, without limitation, polymers, glues,adhesives, metals, and composites.

In the illustrated arrangement of FIG. 14, the active material 36 ispositioned on both of the first and second flexible structures 32, 34.It should be noted that the locations of the active materials 36 on theflexible structures 32, 34 shown in the figures are purely illustrative,and the invention is not limited to any specific locations of activematerials. In particular embodiments, the active material is coextensivewith the respective flexible structure. In other embodiments, the activematerial extends over only a portion of the flexible structure. Theactive material can take the form of a single continuous portion.Alternatively, multiple discontinuous portions of the active materialcan be employed to actuate respective ones of the flexible structures. Asuitable active material is one, which is capable of creating stressresulting from an electrical stimulus. Examples of suitable activematerial are provided above with reference to FIGS. 15 and 16.

As discussed above with reference to FIG. 2, a synthetic jet driver 40may be provided to apply an electrical current to the at least oneactive material 36, to form streams of ambient air. The synthetic jetdriver 40 may be located within the chassis or may be remotely located.

A number of different fin configurations can be employed in theabove-described chassis. For the arrangements depicted in FIGS. 1 and 2,the fins are plate fins arranged in a regular one-dimensional array.FIG. 17 illustrates a v-groove plate fin configuration. Under specificcircumstances, a v-groove configuration may exhibit enhanced coolingrelative to a conventional plate fin arrangement shown for example inFIGS. 1 and 2. It should be noted that although FIG. 17 shows a v-grooveconfiguration with symmetric v-grooves, the invention is not limited tothese arrangements and can also employ asymmetric v-grooveconfigurations. Similarly, although FIG. 17 shows v-grooves withcenterlines aligned with the respective centerlines of the jets, offsetarrangements may also be employed, in which the centerlines of thev-grooves are offset from the centerlines of the jets. Similarly,combinations of these arrangements may also be employed (asymmetricv-grooves that are offset for the respective jets).

Particular features of chassis 10 with distributed jet cooling aredescribed with reference to FIGS. 15, 16, 18 and 19. As discussed abovewith reference to FIGS. 1 and 2, the chassis 10 includes one or moresidewalls 12 defining a volume (not shown) configured to substantiallysurround one or more heat generating components not shown) positionedwithin the volume. The chassis 10 further includes at least one array offins 14 thermally coupled to a respective one of the one or moresidewalls and at least one synthetic jet assembly 30 comprising a numberof single orifice synthetic jets 2 disposed on a side 15, 16 of arespective one of the at least one array of fins. As indicated, forexample in FIG. 15, each of the single orifice synthetic jets 2 isconfigured to direct a jet at an end of a respective one of the fins 14(an “on fin” configuration). Beneficially, experimental test resultsshowed that on fin configurations (jet exit centerline is aligned withthe respective fin) exhibited enhanced cooling performance relative toarrangements in which the jets were directed between neighboring fins.

As indicated, for example in FIGS. 15 and 16, each of the single orificejets 2 comprises an orifice. For particular embodiments, at least asubset of the orifices have an opening length L in a range of aboutthree (3) millimeters (mm) to about seventeen (17) mm, and the distanced (see, for example, FIG. 18) between a respective one of the orificesand the respective end of the fin is in a range of about one millimeter(mm) to about seven (7) mm. As shown for example, in FIGS. 20 and 21,the opening length L for the orifice 39 is the length of the chordformed by the ends of the walls (for example, silicon walls) that definethe orifice. Thus, looking “head on” at the jet (facing the orifice),the opening length L is the 2-D length of the opening. More generally,the orifice size is selected to be proportional to the fin spacing toachieve optimal cooling, and to provide adequate cooling/vortexgeneration, the jets are optimally located with the fins. According to amore particular embodiment, at least a subset of the orifices have anopening length L in a range of about eight (8) mm to about seventeen(17) mm, and still more particularly, in a range of about thirteen (13)mm to about seventeen (17) mm. Experimental test results showed that 15mm orifice jets exhibited enhanced cooling performance relative to 8 mmorifice jets.

According to a more particular embodiment, the distance d is in a rangeof about one millimeter (mm) to about 3 mm. In one non-limiting examplethe distance d between the orifice and the end of the fin is about twomillimeters. As used here, the term “about” should be construed to meanwithin plus/minus ten percent of the stated value. Experimental testresults showed similar cooling for jets spaced 10 mm and 2 mm from therespective fins. Hence, a two (2) mm spacing is preferred to reduce thespace taken by jet mountings.

FIG. 19 shows three different “on fin” arrangements of synthetic jetsand fins. 24. For the first configuration shown in FIG. 19 (labeled “3jets”), each synthetic jet assembly comprises three single orificesynthetic jets 2, and the spacing between neighboring single orificesynthetic jets is every fourth fin. More generally, an integer number Nof single orifice synthetic jets 2 may be used, where the spacingbetween neighboring single orifice synthetic jets is every fourth fin.For the first configuration shown in FIG. 19, N=3. For a chassis that istwo times as wide as the tested heat sink, N=6, for example. As shownfor example in FIG. 19, the phrase “every fourth fin” should beunderstood to mean every fourth fin for the case of a one-dimensionalarray of plate fins. Similarly, this refers to every fourth row of finsfor the case of a two-dimensional array of pin fins.

For the second configuration shown in FIG. 19 (labeled “4 jets”), eachsynthetic jet assembly comprises four single orifice synthetic jets 2,and the spacing between neighboring single orifice synthetic jets 2 isevery third fin. More generally, an integer number N of single orificesynthetic jets 2 may be used, where the spacing between neighboringsingle orifice synthetic jets is every third fin. For the secondconfiguration shown in FIG. 19, N=4. For a chassis that is 150% as wideas the tested heat sink, N=6, for example. As shown for example in FIG.19, the phrase “every third fin” should be understood to mean everythird fin for the case of a one dimensional array of plate fins andevery third row of fins for the case of a two dimensional array of pinfins.

For the third configuration shown in FIG. 19 (labeled “5 jets”), eachsynthetic jet assembly comprises five single orifice synthetic jets 2,and the spacing between neighboring single orifice synthetic jets 2 isevery other fin. More generally, an integer number N of single orificesynthetic jets 2 may be used, where the spacing between neighboringsingle orifice synthetic jets is every other fin. For the secondconfiguration shown in FIG. 19, N=5. However, the specific value of Nmay vary. As shown for example in FIG. 19, the phrase “every other fin”should be understood to mean every other fin for the case of plate finsand every other row of fins for the case of a two dimensional array ofpin fins.

Although cooling enhancement increases with the number of jets, thistrend decreases with increasing number of jets. Switching from threejets to four jets, the overall enhancement changes from 2.5 to 3.2,rising by 0.7, whereas it increases by 0.3 when switching from four jetsto five jets. This indicates decrease of COP (coefficient ofperformance) as the number of jets increases. COP in the present work isdefined as the ratio of heat dissipation to power consumption ofsynthetic jets. These results were obtained for a series of multiple jettests for on-fin arrangements using synthetic jets with 15 mm orificesthat were placed two mm below a finned plate. For these arrangements,switching from three jets to four jets caused COP to slightly decreasefrom 49 to 47. However, switching from four jets to five jets caused COPto decrease from 47 to 42. Beneficially, using four jets achieved 300%enhancement over natural convection with a coefficient of performance of47.

Although only certain features of the invention have been illustratedand described herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1. A chassis with distributed jet cooling, the chassis comprising: oneor more sidewalls defining a volume configured to substantially surroundone or more heat generating components positioned within the volume; atleast one array of fins thermally coupled to a respective one of the oneor more sidewalls; at least one synthetic jet assembly comprising amulti-orifice synthetic jet or a plurality of single orifice syntheticjets disposed on a side of a respective one of the at least one array offins; a clip attached to a respective one of the at least one syntheticjet assemblies and to a respective one of the one or more sidewalls, theclip providing at least two points of contact with the respective one ofthe at least one synthetic jet assemblies; and a flexible connectorpositioned at each point of contact between the clip and the respectiveone of the at least one synthetic jet assemblies to secure therespective one of the at least one synthetic jet assemblies to the clip.2. The chassis of claim 1, wherein the at least one synthetic jetassembly comprises a plurality of single orifice synthetic jets, whereinat least one of the sidewalls includes a plurality of slots disposed onat least one of the sides of the array of fins, and wherein the clip isinserted into a respective slot to secure the respective single orificesynthetic jet to the sidewall.
 3. The chassis of claim 2, wherein theclip comprises a base sized to clip into a respective slot to secure therespective single orifice synthetic jet to the sidewall.
 4. The chassisof claim 3, wherein the base includes an opening formed therein sized toreceive a bolt that further secures the respective single orificesynthetic jet to the sidewall
 5. The chassis of claim 1, wherein theflexible connector comprises a silicone ear applied between a respectivepoint of contact between the clip and the respective one of the at leastone synthetic jet assemblies
 6. The chassis of claim 1, wherein the atleast one synthetic jet assembly comprises a plurality of single orificesynthetic jets, each of the clips having a bent portion that is fastenedto a respective one of the one or more sidewalls.
 7. The chassis ofclaim 6, wherein the bent portion includes an opening formed thereinsized to receive a bolt that further secures the respective singleorifice synthetic jet to the sidewall
 8. The chassis of claim 1, whereinthe clip comprises an e-clip that provides three points of contact withthe respective one of the at least one synthetic jet assemblies
 9. Thechassis of claim 1, wherein the clip comprises a c-clip that providestwo points of contact with the respective one of the at least onesynthetic jet assemblies.
 10. A chassis with distributed jet cooling,the chassis comprising: one or more sidewalls defining a volumeconfigured to substantially surround one or more heat generatingcomponents positioned within the volume; at least one array of finsthermally coupled to a respective one of the one or more sidewalls, theat least one array of fins including a first end and a second endpositioned generally at opposite edges of the respective one of the oneor more sidewalls; a plurality of synthetic jets positioned at the firstend or the second end of the at least one array of fins; a clip attachedto a respective one of the plurality of synthetic jets and to arespective one of the one or more sidewalls, the clip at least partiallysurrounding the respective one of the plurality of synthetic jets to asto secure the synthetic thereto; and a flexible connector positionedbetween a clip and its respective one of the plurality of synthetic jetsto secure the respective one of the plurality of synthetic jets to theclip.
 11. The chassis of claim 10, wherein at least one of the sidewallsincludes a plurality of slots formed therein adjacent at least one ofthe first end or the second end of the array of fins, and wherein theclip is inserted into a respective slot to secure the respectivesynthetic jet to the sidewall.
 12. The chassis of claim 11, wherein theclip comprises a base sized to clip into a respective slot to secure therespective synthetic jet to the sidewall.
 13. The chassis of claim 10,wherein the flexible connector comprises silicone ears applied at atleast two points between a clip and its respective synthetic jet. 14.The chassis of claim 10, wherein the clip includes a bent portion thatis fastened to a respective one of the one or more sidewalls.
 15. Thechassis of claim 14, wherein the bent portion includes an opening formedtherein sized to receive a bolt that further secures the respectivesynthetic jet to the sidewall
 16. The chassis of claim 10, wherein theclip comprises one of: an e-clip that provides three points of contactwith the respective synthetic jet; or a c-clip that provides two pointsof contact with the respective synthetic jet.
 17. The chassis of claim10, wherein each of the synthetic jets comprises: a first flexiblestructure; a second flexible structure; at least one active materialcoupled to at least one of the first and second flexible structures; anda compliant wall positioned between the first and second flexiblestructures and defining a chamber, wherein the compliant wall defines atleast on orifice for facilitating fluid communication between thechamber and an ambient environment of the fins.
 18. A chassis withdistributed jet cooling, wherein the chassis is manufactured by aprocess comprising the steps of: providing a chassis including: one ormore sidewalls defining a volume configured to substantially surroundone or more heat generating components positioned within the volume; andat least one array of fins thermally coupled to a respective one of theone or more sidewalls; and securing a plurality of synthetic jets to arespective one of the one or more sidewalls such that the plurality ofsynthetic jets is positioned at one end of the at least one array offins; wherein securing each of the plurality of synthetic jetscomprises: positioning a clip at least partially around a respective oneof the plurality of synthetic jets; applying a silicone material betweenthe clip and the synthetic jet at at least two locations such that atleast two points of contact are present between the clip and thesynthetic jet, so as to secure the synthetic jet to the clip; andaffixing the clip to a respective one of the one or more sidewalls tofixedly position the synthetic jet relative to the at least one array offins.
 19. The chassis of claim 18, wherein in affixing the clip, theprocess further comprises securing a base of the clip within a slotformed in a respective one of the one or more sidewalls to secure theclip to the sidewall.
 20. The chassis of claim 18, wherein in affixingthe clip, the process further comprises bolting the clip to a respectiveone of the one or more sidewalls to secure the clip to the sidewall,wherein the bolt is inserted through a bent portion of the clip that isadjacent the sidewall.